Tablet fob use in fabricating



Sept. 12, 1939. H, |BBERT0N 2,172,564

`'I'ABLET FOR USE I N FABRICATING ELECTROTYPES Original Filed May 4, 1934 2 Sheets-Sheet 1 'Ill/1111,1

2/ W Herber zlbberZ-On/ Spt. 12, 1939. H. LIBBERTON TABLET FOR USE IN FABRICATING ELECTROTYPES 2 Sheets-Shet 2 Oi'iginal Filed May 4, 1934 1r i... f

Patented Sept. 12, 1939 I UNITED"- STATES arassi TABLET FOR USE IN FABRICATING ELECTROTYPES Herbert Libberton, Chicago, Ill., assignor, by direct 'and mesne assignments, to Tenak Products Company, Chicago, Ill., a corporation of Illinois Application May 4, 1934, serial Ne. '123,940 Benewed June 20, 1938 r i 21 Claima' My invention relates in general to printing and has more particularreference to means for and method of making'electrotype printing plates, the invention having special reference to a moldable tablet, for use in the fabrication of electrotypes, and to methods and apparatus for making the tablet, the same being an improvement and continuation in part of the invention set forth in my co-pending application, Serial Number 647,504, med December 16, 1982.

At present, electrotype plates are made by electroplating the surface of wax or lead tablets in which the image .to be reproduced has previously been molded.

Among the difliculties and disadvantages en'- countered in using lead tablets, is the .enormous pressure required to mold the lead, which prevents set-up type from being directly molded in the lead tablet, consequently, as is well known in the art, it is not practical to mold lead tablets directly with ,a so-called mixed form", comprisingset-up type and other kinds of form, such as previously prepared zinc etchings,. half-tones, and the like, which can be used for lead molding. Another distinct disadvantage encountered in molding lead tablets is the powerful presses required in making the impression. It is also virtually impossible commercially to transport the relatively soft, heavy lead plates after molding as by mail, freight, or express, in case it may be desired to electroplate the molded tablet at a place other than where the tablet is impressed. Unless extraordinary care is taken in packing and transporting the tablets, they will be irreparably damaged in transit and rendered unfit for use. The same disadvantage exists where the tablets are of wax, which, being fairly soft, cannot successfully withstand. the shocks. and jars of transportation either before or after be- 40 ing molded, but must be handled with care and plated immediately.

Among the many other dii'culties and disadvantages'encountered in using Wax tabletsis the expense of making the tablets in the shop 45 where used, involving, as vit does, the mussy and untidy operation of applying heated wax to a hacking plate; the shaving of the wax to proper thickness after application; the labor and expense of maintaining an oven to fiash the plate to render the wax soft just before the tablet is placed in the press; the several expert processing steps performed upon the tablet after pressing, including shaving, flashng, building, and graphitizing the tablet in order to condition it for the plating bath; the necessary heating of the tablet and plate in order to strip them apart after the tablet has been plated; andthe fact that the Wax does not receive an absolutely true impression because its composition and temperature are not and can not be maintained uniform throughout the tablet no matter how carefully controlled; and because the processing steps of shaving, fiashing, building, and graphitizing distort the impressed tablet, however slightly, before it is plated. Graphitizing also is a dirty, mussy, and 'untidy process.

An important object of the invention, there-4, fore, is to provide a molding plate or tablet, more especially adapted for electroplating, which can be molded cold under relatively low pressures to 15 take a clear, accurate, and undistorted impression from any kind of form, matrix, or die which may include set-up type, engravings, etchings, half-tones, or any other form, to provide a tablet which requires no "building or other processing treatment after molding to condition it for platl ing; to provide a tablet' which is inexpensiveto manufacture, light in weight, easily handled, and 4 commercially transported either before or after impression, which may be stored without deterioration and which, for these reasons, can be manufactured at a central factory and shipped to the customer ready for pressing and then may be sent to a remote electroplating plant without danger of damage or dete'rioration in transit.

' Another important object is to eliminate the various difficulties which arise in electrotyping because of the inherentfdisadvantages of using lead or wax as a molding and plating medium, including the Adusty and dirty conditions inherent to the' necessary graphitizing step when wax molding tablets are used;

Another' important object is to provide athin fiexible, yet self-supporting, tablet adapted to be molded in cold condition to receive and accurately hold an impression in spite of minor deflection imparted thereto in handling the plate after molding.

'Another object is to provide a relatively thin molding tablet for use in making electrotypes, which can be deformed throughout its `entire thickness to take the general outline of a formand which in its surface will take and hold the spe'cific impression of the form, and which is sufllciently self-supporting to hold its shape without distortion after being molded. 4

Another object resides in the method of molding a tablet for electrotyping, which consists in molding a. relatively thin, yet stifl and self-supporting plate to the general shape of the matrix, 65

while simultaneoully making a specific surface impression in a molding layer carried by the backt ing plate.

Another object a to provide a moldable tablet having a relatvely inelastic surface adapted to receive and hold the specific imprint of the form.

Another important object is to provide a composite molding tablet for use in electrotyping and including a thin booking plate adapted to be distorted by a molding form and after distortion to retain its shape by absorbing minor defiections, such as may occur in ordinary careful handllng, without acquiring a permanent set, and having a relatvely inelastic moldable surface thereon capable of receiving accurate impressions from a form of any character.

Another object resides in utilizing a thin sheet of annealed metal,`such as 'copper or aluminum, as therelatively stifl hacking plate.-

Another object is to provide means for and method of molding the strip continuously.

Another object is to provide a molding tablet having a molding surface of relatvely soft moldable material adapted to receive a specific surface imprint from a molding form backed with a relatvely stff material adapted to be deformed to the general contour of the form and to support the molding su'rface against distortion as it is stripped from the form.

Another object is to apply an infiniteiy thin layer of electrical conducting materiaL'preferably in finely divided condition, on the surface of the tablet to enable the reproduction, on said surface, of the finest shadow impressions at pressures suffi- .cient only to mold the impression in the tablet 40.' and without requiring additional pressure to deform the conduoting material.

Another important object resides in providing a new and improved material for usemore particularly, in making molds for electrotyping.

Another important object is to utilize a Wax, together with a toughening medium, such as rubber or balata, in a moldable tablet of the character described. t

Another important object is to utilize a wax, together with a resilient gum, such as rubber, or balata,` as a toughening agent, in a moldable tablet of the character described.

Another important object is to provide a molding composition, including waxes and a toughening agent, together with a medium for increasing the adhesive qualities of the composition when hot so as to facilitate adhesion of the material on a backing member.

Another object is to adhere a molding compound on a backing by interposing therebetween a bonding layer strongly adhesive to both the backing and the compound.

Another object resides in applying a parting medium in the moldable surface of the composition to faciiitate stripping of the eleotrotype from the molded form.

Another object resides `in using powdered' metals, such as copper, bronzes, or mica dust as a parting material.

Another important object is to apply an electrical 'conducting medium on the surface of the tablet overlying the parting medium and to securely adhere the conducting medium in place.

Another important object is to provide a suitablel apparatus for building up the tablet as a continuous process. v

Another important object resides in providing methods of building up the tablet including the adhering of the moldable layer on the hacking sheet, the parting layer on the moldable layer and the conducting layer o n the parting layer, and including the application of layers of uniform thickness and smooth fine surface texture.

Another object resides in anneaiing the hacking sheet during the application of the Iayers.

Still another object resides in the reorganization and simplification of electrotyping methods and technique through the use of my new molding material.

Numerous other objects and advantages of the invention will be apparent from the following description, which, taken in connection with the accompanying drawings, discloses preferred embodiments of the invention.

Referring to the drawings:

`Figure 1 is a perspective view of a molding tablet embodying my invention;

Figure 2 is a section taken along line 2-2 in Figure 1;

Figure 3 is a diagrammatic view of a press illustrating a preferred mode of molding the mate- Figure 8 illustrates the application of a hacking to the eleotrotype;

Figure 9 is a section taken through the electrotype as backed with lead and ready for blocking;

Figure 10 is an enlarged section through a tablet 'embodying my present invention;

Figure 11 is a diagrammatic view of apparatus for building up the tablet in a continuous. proc- BSS;

tion of the tablet building apparatus; Figures 13, 14, and 15 are sectional views take substantially along lines |3-|3, |5-l5, respectively in Figure 11;

Figures 16, 17, 18, and 19 are greatly enlarged sectional views of the surface portions of the tablet at various stages in its fabrication; and

Figure 20 is a diagrammatic view of a continu-' ously Operating press'for molding the sheet material continuously.

To illustrate my invention, I have shown on the drawings, a tablet made in accordanc'e withmtheteachings of my present invention andA adapted'to accurately receive, in its surface, impressions especially well suited for eiectrotyping.

'The tablet is relatvely thin so that it may be deformed throughout its entire thickness in order to receive the general impression vof the molding form and to accommodate the material displaced by the form without causing it to bulge upwardiy of the surface of the plate and thus effect the specific surface configuration impressed by the form. The tablet is stiif enough to be self-supporting and is resilient enough to absorb rninor defiections without becoming distorted so that the portions containing the specific impression will be supported substantially without distor- Figure 12 illustrates a modified form of a por- M-H, and 4 'and without distortion. The tablet'also in its surface is moldable to receive the specific imprint of the molding form or matrix and is inelastic enough to retain an imprint pressed therein, however fine the imprint may be.

The deformed surface of the tablet is adapted to be electroplated, and .the tablet is adapted to release the shell so deposited on its surface without adhering lany deleterious materials on the shell surface and thereby causing blemishes therein after the same is later used as an. elec'- trotype. To this end, I prefer to provide the tablet at or near 'its surface with parting means having the function to promote a clean par-ting between the surface of the sheet and the plated shell. I prefer also to apply on the surface 'of the tablet an electrical conducting material, preferably in finely divided condition, as a film sub- "stantially thinner than the finest printing impressions, i. e. shadow dots" which may be molded on the tablet in order to promote a rapid and uniform deposit of material thereon in the shell-forming operation and at the same time permit the finest impressions to be formed on the tablet without requiring excessive molding pressures to deform the conducting layer.

.The tablet may be made in several Ways and of various materials. It may be of homogeneous structure in which the material has 'the requisite characteristics to enable the tablet to be formed as heretofore described. Preferably, however, the tablet is of laminated structure wherein the surface comprises a layer of relatively soft material suitable to receive and retain the specific form imprint while a substantially stifif underlying layer is provided to support the surface layer and absorb the general displacement of material which occurs when the plate is formed.

The laminated tablet structure is par-ticularly desirable where themolding form comprises setup type, that is to say, where some or all of thel molded impressions are relatively deep. In such cases it is desirable to supply. a backing layer to support themoldable layer and to absorb at least a part of the general impression. Where the tablet is to be shipped after molding, a hacking of relatively strong material is also desirable to prevent distortion to` the'molded tablet during transportation.

A relatively stiff hacking vlayer is preferable even where only fine impressions are to be made in order to support .the relatively soft portions forming the molding surface and prevent distor- -tion thereof during the stripping of the molded tablet from. the molding form or matrix and during the subsequent handling of the tablet after molding.

In the'illustrated embodiment, the tablet is shown as .comprising a hacking |3 and a moldable layer 15, the backing being preferably of relatively thin,l resilient sheet material having an' configuration of the press and when so deformed sheet.

retain its resilient layer supporting characteristics.

I prefer'to form the hacking 13 of annealed aluminum sheets approximately .006 of' an inch thick,' In 'certain cases, depending somewhat upon service requirements, satisfactory results may be had by applyingthe layer |5 to a backing formed of 'cardboard paper or sheet copper, and I do not wish to limit the, inventon to any specific hacking material but any tliin sheet having the requisite resilient stiffness and deformability may be utilized, or, in some instances heretofore explained,e1iminated entirely. Where a backing is used however, the molding layer 15 need not have the mechanical stren'gth necessary when the molding layer is unsupported. I have discovered that a molding composition, including balata or -rubber gum and certain waxes and resins, has certain desirable characteristics when used with a hacking layer. The compound, containing balata or rubber, is comparatively inelastic and tough when cold and can be molded in. substantially cold condition to accurately receive a specific impression of the finest texture used in printing. The molding composition, however, when hot, is fluid enough to permit the same to be applied as a relatively thin, uniformA layer, approximately '.015 of an inch thick, to the backing sheet |3.

The balata or rubber ingredient has the characteristic of imparting toughness to waxes with which it is mixed so that by using balata or rubber as an -ingredient, and I prefer'to use lSurinam sheet balata or standard rubber smoked sheet, although reclaimed rubber may also be used for the purpose, the Wax ingredient is modified and vtoughened vto-the end that the molding composition'is exceedingl-y tough while retaining' the comparatively inelastic character of the wax. Apparently there is a change in the internal structure of the waxes, more than a mere mixing of ingredients, which produces a uniform, homogeneous, slightly fiexible, yet inelastic'and exceedingly tough molding material. Balata also is exceedingly sticky when hot and will maintain'a bond, formed while hot, even after cooling to a non-sticky condition. This -characteristic appears to an extent in the reisulting composition' so that/if applied to the plate |3, while hot, the layer |5, after cooling, adheres strongly because of the balata ingredient.

I prefer, however, to utilize an adhering or bonding layer H between the moldable layer and the hacking sheet, particularly where the hacking sheet is of metal and the compound includes rubber, since rubber is not as adhesive as balata. Even where balata is used in the molding compound, a bonding layer |4 is desirable. This adhering layer is preferably an emulsion of asphalt in water. The emulsion is thinned to brushing consistency and applied asa uniform thin coat with a scraper after which heat is applied to'evaporate the water, leaving a water ,'insoluble asphalt coating of uniform thickness over the entire area of the' backing With this coating, which firmly adhe'res. on the smooth surface of the metallic backing sheet, the moldable rubber and Wax compound will form a firm bond. 'The asphalt, I prefer to use for-the bonding coating,-is a dispersion of asphalt in water, using four percent clay as an emulsifying agent. Alternatively, a solution' of asphalt in benzine or gasoline may be used instead of 'the aqueous emulsion.

v I may, in some cases, form the bonding layer` Ill by using a bonding solution comprising balata' gum and a resin, such as cumarone. This is applied warm to the 'plate -|3 and adheres more strongly after .cooling than does by molding compounds. vThis bonding layer H forms a base to which the layer IS will adhere even more tenaciously than if applied directly to the plate.

For the fwax' ingredient of the molding composition, whether the main ingredient is rubber or balata, I- prefer to use a mixture of beeswax and carnauba wax, since these are not only moldable but beeswax 'has adhesive characteristics which are retained in the composition to assist in holding the layer 15 on the plate |3 while the carnauba wax is of unctuous character and makes the matrix easy to pull out of the molded plate. Any other wax or waxes pro- 'viding' these characteristics may, of course, be

used. Paraflin, preferably of the softer grades, and 'other waxes, such as ozokerite, may be used for the purposes. i

The resin ingredient is preferably paracumarone resin and-is to impart additional adhesiveness in the composition without destroying its toughness or rendering it elastic. Other suitable resins, adapted to render the composi-- tion adhesive, may, of course, be substituted for the paracumarone resin.

A filler, such as-zinc oxide or Silica, or other suitable material for toughening the composition, may be used, although not essential.

As a preferred example of a compound, using balata as the main ingredient, I may make the composition' by mixing the ingredients in accordance with the following formula:

Parts by Weight lata 'gum 6 Paracumarone resin 3 Beeswax 3 Carnauba was 2 Zinc oxide 7 As a preferred example of a moldable compound, using rubber as the main ingredient, I make the composition by mixing the ingredients in accordance with the following formula:

Parts by Weight Smoked sheet rubber 7 Paracumarone resin 3 Ozokerit- '5 Paraflin (M. P. 134; F.) 3 Powdered silioa 211 ,balata varies considerably in composition, quality and available supply.

- Reclaimed rubber may also be used as a substitute for the smoked Sheet rubber, the latter being specified as a well known rubber standard of negligible Variation in quality. Smoked sheet out with acid. The rubber precipitateis then milled out in sheets of approximately /a inch in thickness and smoked.

The ingredients, whether rubber or balata is used, are mixed together as in a rubber mill and the composition is immediately ready for use. It may be applied to the hacking plate simply by flowing the moldable material as a layer IS onto the backing layer |3, which has preferably previously had a fllm of suitable adhesive material applied thereto to form a bonding layer ll. The backing layer with the layer |5 thereon is then passed between squeezing rollers which are adapted to cool and solidify the molding compound, and, at the same time, form the layer |5 to uniform thickness of the order of .006 inch throughout the extent of the tablet. Upon cooling, the composition adheres to the hacking plate with such tenacity as to prevent separation unless the layers are forcibly and intentionally stripped apart.

After the layer |5 has been applied, a thin fllm or skin IS of a suitable electrical conducting material, preferably in flnely divided form and preferably substantially less than .0005 inch in thickness, is applied to the exposed or impression-receiving surface of the layer IS. This skin may be formed as a layer of powdered graphite which is brushed on to the surface of the layer |5. I'he graphite may be applied, in the case of a.layer comprising rubber, almost immediately after the layer cools but where the layer l5 comprises balata, it is preferable to permit the layer to set for an appreciable period, say twenty-four hours, before the graphite is applied.v

By forming a conducting layer of substantially less than .0005 inch in thickness, I am able to provide for molding the finest reproducible printing impression, i. e., a shadow dot. which is of the order of .0005 inch in width and depth without appreciable resistance to molding by the internal friction of the conducting' layer. The conducting layer isf'merely forced into the depression by lateral bending. The impression is not made in the layer itself and consequently the molding pressure does not have to be increased to overcome the internal friction of the layermaterial, it being merely necessary to bend the layer material into the depression formed in the relatively soft material of the layer |5. consequently, the molding' pressure required is merely that required tointernally deform the material of the layer IS. By using graphite, moreover, a substantially uniform conducting film or skin is formed over the e'ntire surface of the moldable layer, and the graphite flakes of the conducting -layer will slip during the molding process and thus be forced more easily into the molded impressions covering the bottoms 'as`well as the sides thereof and promoting the rapid formation of a plated shell when the molded tablet is immersed in a plating bath. Graphite, moreover, parts readily from the plated shell without leaving any materials on the surface of the Shell, which might form blemishes in the finished electrotype. Any graphite adhering to the shell may be brushed off and even if not removed will not form spots or blemishes in the electrotype.

I prefer also to apply a parting layer |8 in the moldable layer behind the electrical conducting skin 16, especially where the latter is formed of graphite, in order to facilitate stripping the tablet from the shell. It is preferable to use, as a parting medium, a material which has no reaction with the electroplating path in which the The conducting layer I O may then be applied v upon the parting layer ll. In some instances. u/'particularly where graphite is used in the conlducting layer, an adhesive solution 2B is necessary between the parting and electrical conducting layers 'since graphite does not readily adhere to the parting material. For this purpose. a number of adhesive compounds are available, such, for instance, as a solution of stearic acid in alcohol, but I prefer to use anl aqueous emulsion of wax, preferably carnauba wax. I prefer also to;include an animaly oil in the emulsion since operation.

I have found that the following composition isespecially effective as an adhesive for the purpose mentioned:

30. Solution A Water o ubic centimeters-- 125- Triethanolamine grams.. 3

, Solution B 35 Carnauba wax i grams 18 Butter fat do 6 ;Stearic acid do 3 Solution A is warmed to approximately`212 F., Solution B is melted together and poured into the warmed Solution A at approximately the same temperature, viz: 212 F. Thirty-five cubic centimeters of ethyl-al'cohol is added as the mixture cools. The resulting mixture is spread evenly as `with a brush, felt pad or other suitable applicator over the partin'g layer and allowed to dry. To

this, the graphite,` forming the conducting layer, adheres evenly with al firm bond.

In Figures 11 `through 15,. I have shown apparatusfor building up my' improved molding tablet as a continuousprocess. In'this apparatus, the sheet, forming the-hacking plate IS, is progressively'advanced through devices adapted to apply'the several coatings or iayers.

In the preferred form of the apparatus shown in Figure 11, the sheet is passed through a device 46 for applyingthe bonding layer ll, an oven 52 for drying the bonding layer, a device 58 for applying the moldable layer IS, a layer cooling and spreading' device 62,, a brushing device 16 for applying the parting layer |8, a iiashing oven for producing an adhesive layer 20 above the parting layer and a brushing device 82 similar to the delvice '[8 for applying the conducting layer l-. In

- preferably fiat friction spring or other pressing device being utilized to hold the strip snugly 76 I find that the animal fat helps in the releasing' the'alternate apparatus, shown in Flgure 12, theagainst the roller. After passing the roller '43,

lthe sheet enters the device 4|,.which comprises a reservoir ll containin'g a material adapted to form the bonding layer Il. 'In passing through the reservoir l'l, the strip IS passes over and is supported by apreferably heated' backing plate 49. the reservoir being erected above the plate 49,

s'o that the bonding material is applied to the upper surface of the sheet i! as it travels through the reservoir. The hacking plate ll is preferably inclined so that the sheet enters at the lower end of the reservoir through a slot in the walls thereof suiiiciently wide to admit the sheet II while preventing the escape ofv the bonding material, and the sheet passes' out through an outlet opening in the upper portions of'the reservolr at .the upper end of the hacking' plate 40, the edges of the reservo'ir casing deiiningthe outlet opening forming a scraper Il asvshown in Figure 13, permitting the sheet |3-to4arry a'substantially uniform' layer of the bonding material with it through the opening 8|. After passing from the reservoir l'l, the strip IIS, carrying with it a layer ll of the bonding material, passes into'a warming oven 52 comprising a casing II includin'g heaters 55 for the purposeof evaporating the moisture content of the bonding'material. At the upper end of the casing 53, the sheet travels over a roller 51 and receives a layer of moldable material IS from the spreading device i. which ,preferably comprises a reservoir having an outlet `B9 disp'osed immediately above the roller ll. The roller I'l may be journaled as shown in the side walls of the case 53 and the casing is preferably arranged to partially enclosethe reservoir 59 so thatthe heat rising through the casing 53 from' the heaters 'I may serve to warm the materiall contained in the reservoirj! and' keep the same sufiiciently ,fiuid for .application to the sheet as it travels around the roller I'l.

The reservoir ,59 also has an adjustable opening defined by a scraper or spreader-member II shiftably mounted on the. walls of the reservoir 58 so that the lower edge of the scraper member 8| may be positioned at a determinable distance above the upper surface of the sheet II as the same passes around the roller Il in order to vary the thickness of the layer-of moldable material which is permitted to escape from the reservoir layer I! as it passes the rollers 03, I interpose between the sheet and the lower roller II, that is to say, the roller that faces the back or uncoated,

surface of the backing sheet II, a relatively large Imetallic cylinder il around which the strip travels in passing between the rollers Il. This cylinder dips into a cooling bath I'I and serves to chili the plate IS and the layer I I. The uppermost of the rollers 03, that is to say, the roller which engagesthe layer il, is preferably cooled articially as by circulating water andlis also -wetted with a solution applied to the surface of the roller from a reservoir I. through the intermediary of solution-applying rollers 1|. This wetting solution is preferably composed -of one part of alcohol and ght parts of'w'ater with ,three percent-of asui le alkali.suchas am- 78 'is delivered` through the devices for monia. The purpose of the wetting solution'is to prevent adhesion between the surface of the layer IS and the forming'roller 63. The cooling solution 61, into which the cooling cylinder 65.

immerses during its rotation, is also preferably a wetting solution in order to preveht adhesion between the cooling cylinder O! and any of the material of the layer IS, which may be squeezed out laterally beyond the edges of the hacking strip I3 and thus come in contact with the cooling cylinder 65. The coated strip Il leaves the cooling cylinder S5 by passing around the guide roller 13 and passes into the parting layer applying device 16, which comprises a supporting plate 15 above which is mountecl a brush 11 or other suit-'-' able device for applying powdered material upon the upper surface of the moldable layer IS. As heretofore described, I prefer to utilize, as a parting material, powdered copper, copper-bronze, powdered mica, or any suitable parting material which `is substantially inert to the action of the plating bath. The brush 11 is preferably enclosed in a housing 19 and is partially enclosed i within the housing by means of a bame II; The brush rotates preferably in the direction shown by the arrow in Figure ll so that the powdered material is continuously thrown over the baille 8| and dropped through thel channel 83 upon the upper surface of the moldable layer as the strip is, advanced beneath the brushlng device. The brush then presses the material onto the upper surface of the moldable layer to forma layer of the parting material on the upper surface of.the moldable layer substantlally as shown in Figura 16 of the drawings, the excess of material being brushed off and delivered in-the casing 18 into the channel 83 as heretofore mentioned.

After leaving the brushing device 11, the strip applying the conducting layer IS.

As heretofore described, I prefer to use graphite as the conducting material and since graphite Will not readily adhere to the powdered bronzle of the parting layer, I may form an adhesive coating or layer 20 upon the parting layer before applying tle 'conducting layer. This may be` accomplished by fiashing the surface of the sheet by passing it through an oven as shown in Figure 11. The fiashing oven is simply a device for heating the surface of the strip to cause the same to flow slightly. This will cause the material of the parting layer to become embedded slightly below the upper surface of the moldable layer I5 substantially as shown in Figure 17 of the drawings.

Where it is desired to apply a separate adhesive coating above the parting layer instead of fiashing the surface, the sheet, after emerging from the brushing device 11, may be passed through an adhesive applicator 86, comprising a roller 81, above which is mounted a reservoii' 89 containing a suitable adhesive: compound, the reservoir having a discharge opening 9| across .which the upper surface of the sheet is carried in passing around the roller 81. As the sheet is carried past the discharge opening of the 'reservoir 39, the film 2B of' adhesive material is deposited upon the upper surface of the sheet substantially as shown in Figure 18 of the drawings by means of the brushing or'wiping devices 93, mounted at said discharge opening. After passing from between the roller 81 and the adhesive-applying deviceA 93, the sheet is preferably passed through a drying oven or similar device in order to dry the adhesive coating and to pro- `duce the structure shown in 18. Graphite for the conducting layer 'maybe applied`4 to the upper surface of the sheet as it comes ;from the Q6 by means` of a brush 83 mounted above'a supporting plate 85 and including a casing 81 and ballle 89 substantially similar tothe brush 11 and its associated, bai'lie and support plate, in order to produce the final product substantially as showh in Flgure 19. The flnished product may be cut in strips as it is delivered from the building apparatus, or may be rolled up as shown at 99.

In order to use the tablet in the preparatlon of electrotypes, a sheet of the material is jarranged preferably on a somewhat resillent block |1 in a press |9, the tablet being arranged with the layer |5 facing upwardly; A form 2| of any suitable character is deposited face downwardly upon the tablet and the press actuated to force the matrix into the layer IS. It is not necessary to utilize excessive pressures in order to form the tablet but pressures, such as are. ordinarily used in the pressing of the ordinary wax tablets may be employed. It is not,however, necessary to heat the tablet of my present'invention before pressing it as is the case with the ordinary wax tablets. After being impressed with the image to be reproduced, the tablet has an impression substantially as shown in Figures 4 and 5 of the drawings and it will be noticed that the resilient block I1 permits the hacking plate l3 to receive 'general deformations conforming substantially with the specific impressions received by the layer IS, and promotes the bonding effect between the layer IS and the hacking plate so that the chances of separation of the`layers Il and IB, after the tablet'has been pressed intothe desired configuration, are substantially' lessened.

The material behind theV depressions formed' in the tablet is thus removed from the zone where I `the speciflc impression is received and thus relieves the internal pressure set up in the tablet which, if not relieved, would result either in -the rebounding of the impression upon removal of the molding pressure, or in ralsing the surface of the tablet between the depressions which is known as "building". In either case, the final resulting impression would be untrue. By absorbing the internal' pressure by permitting it to deform the entire tablet throughout its thickness so that the reverse side of the tablet also has the general contour of the form, the specific impression on the obverse side of the tablet is preserved exactly as molded by the form.

It is not, of course, essential entlrely to eliminate building between the depressions formed in the-tablet. A certain amount of building is desirable, especially where the space between depressions is of relativelylarge area. The tablet of my invention permits limited uniform building between depressions. Excessive building, however, is eliminated by keeping lthe layer thin to thus permit the entire tablet to be deformed and by maintaining the toughness of the material sufficient to prevent the material flowing freely from under the raised portion of the form and squirting up between the depressions of the tablet. The amount of building may be regulated by controllingthe relative fiuidity of the material forming the layer I. If a greater building is desired, a larger proportion of wax, more particularly thev unctuous Wax ingredient, should be used in preparlng the 'molding material. Where the surface layer IB is*l in the forml of a thin sheet, the layer acts asa skin and eliminates 'flashing oven all'or the adhesive-appling device i awansu.

excessive b'uil'dingfi and`l equalizes' the building throughout the tablet.v i

It will be noted that the tablet may receive simultaneously type impressions' 23 as well as the i type characters and portions adapted to make relatively fine impressions, and this'advantage, as has heretofore been pointed out, is not .present where the lead tablet is used, and even though a 'mixed form can be molded in av wax tablet, the impression -in wax is not as accurate nor as fine as may be had if the teachings of my present invention are' followed.

In-Figure 20, I have shown a device for molding the sheet material to make electroplate molds or mats in a continuous fashion, thus illustrating one of the inherentvaluable characteristics of the molding sheet. This process, which'is ltself new, is particularly adapted to produce molds in quantity. I

The finished molding sheet, as it is delivered from the fabricating apparatus shown in Figures 11 and 12, may be delivered directly into the continuous molding apparatus shown'in 'Figure 20,

I tends .to adhere to the. pattern forms and'to fol- .or may be stored for any lengthof time and/or transported to a molding station andthen delivered to the molding'machine. The molding machine in essence comprises a pair of rollers, one of which 10| carries onel or 'more molding forms l2l corresponding to theform 2| of the flat discontinuous press shown in Figure 3. The other roller |03 has a. resilient portion, such asa layer of rubber ||1 corresponding to the layer ll of the discontinuous' molding press. In the -illustrated embodiment, the layer ll'l is shown as an idle endless belt which is carried on the roller |lJ3. Any suitable means may be provided for adjusting the spacing between the centers.

of the rollers llll and |03 and yielding means lll is preferably provided'to hold the rollers in adjusted, spaced-apart positions, means being also preferably provided for adjustng the tension of the yielding means. The finished moldable sheet is fed between the rollers |0`l `and l03 iwith'its' buckingside |3 facing theyielding material li'l and itsmoldable surface facing the roller carryin'g the pattern forms l2l so that the sheet is molded in accordance with the pattern forms |2| as it pass'es between the rollers. `The sheet low the roller I'lll' Aand may be continuously stripped from the roller hby suitableautomatic stripping ,means comprising', in the illus'tratedA embodiment, aroller vIQ'I' preferably'j having a yielding surface to prevent'injury to the molded face of the Sheet, said roller 'l being .driven with a sjirface speed equal to therateof travel ofthe'inolded sheet. i

The sheet of my present invention continuously molded as above described because of the 'fact that it is substantially selfsustaining yet flexib'le enough tofollow theroller HM and because only low molding pressures are required tozimpress or emboss the 'moldable Sheet.

- able plating bath 2fl`, which may best bezaccomr 'I plishe'd by fastening the formed tablet on a hold- 'After bei'n'g impressed,.,the 'spcificny forined i surface of the layer l5 may additionally handpolished .with graphite if necessary .and then electroplated simply by immersingit in a suiting plate 29, preferably of lead, the tablet being attached/ to the lead plate by means of the tacks 3|, and the plate suspended by means'of a holder 33 from the bar 35. Wherethe layer IS is in the,

form of a metallic sheet, it is, of course, vunnecessary to polish with graphite, since the sheet.

metal layer IS affords an ample conducting medium so 'that the entire impressed surface of thetablet commences to receive a plated shell as soon 'as it is deposited in the plating bath.

As is well understood in the electroplating art,

an electric potential'is applied between the bar' the metallic' portions of. the carrier member 29 I and the hanger 33 to the bar 35 and being exposed to the fluid of the plating bath, will receive a coating of metal.

Where a metallic hacking |3 is used, the edges of the backing, being exposedto the plating fluid and electrically connected to the bar 35, because the tacks 3| pass through the hacking, provide an excellent contact all around the tablet which facilitates the initial deposit vof the plated metal at the' edge of the tablet from whenfce the plated metal spreads inwardly, finally coveringthe entire surface of the tablet.

After the' plating process has beenv carried on sufllciently to 'deposit a metallicfilm of proper thickness upon the grapliitized surface, the tablet may be removed from the plating bath and the deposited film'strippei from the tamet. v

The stripping operation is illustrated in 'Fgure 7 of the 'drawings -and afterthe electroplate 31 has been removed from the tablet, it may be i cleaned and backed with lead 39 as' shown in etchings, engravings, half-tones', and similar' forms andon account of the resilient stiffness vof the backlng `will vretain'the impression's undistorted even when subjected to mo'derately 'rough handling. `It is notpossible' to accomplish this with either lead or waxtablets yof the 'ordinary sort, since Wax does notv accurately; take the relativelyV fineimpressions made byl'et'chings, halftones,and the like, while the pressure required to impress etchings, half-tones, 'and the ,like on lead i plates is so' great as to break or otherwise .dam-

age the relatively large type forms. fIn addition,

wax tablets willnot retain their impressions undistorted vnnless1carefullyvhandlecl in fabrication and, use and .cannotbe transported by common carriers while even lead plates require careful handling and .specialfpackaging for'icommercial transportation.

. Anotherlmportant dvant'ag'eretsid vin'fllminating the 'expense 'of Wax tablets which require space-consuming apparatus in the shop 'and also consume the operators time;

tion of the expense'of :the relativelyheavy lead tablets .by the provision of a'jlightweight ,tablet which incorporates, the advantages of both 'Wax further important advantage is' the`e1imina- I and lead tablets and which eliminates the disadvantages of bothj My tablet being relatively light in Weight, can be shipped at much less cost than the relatively heavy lead tablets and can be shipped safely to the electroplater after being impressed, while Wax tablets, for practical considerations cannot be shipped at all but have to be molded where fabricated and electroplated where molded. My tablet also will take an impression of a fineness and accuracy equal to that accomplished on a lead tablet, at pressures comparable to those required in molding wax tablets so that the relatively expensive, highpressure molding apparatus. now required in pressing lead tablets may be`elimlnated entirely.

It is thought that the invention and numerous of its attendantadvantages will be 'understood from the foregoing description and it is obvious that numerous changes may be made in the form, construction, and arrangement of the several parts without departing from the spirit or scope of my invention, or sacriflcing any of its attendant advantages, the forms herein described being preferred embodiments for the purpose of illustrating my invention.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent is as follows:

1. A moldable tablet for use in the preparation of electrotype, comprising a sheetv of aluminum of predetermined stifl'ness, a binding film on a surface of the sheet, a layer of. moldable material secured to the sheet by said binding film, and a parting layer in the exposed surface of the moldable material.

2. A moldable tablet for use in the preparation of electrotype, comprising a sheet of aluminum of predetermined stiffness, a binding film on a surface of the sheet,4 a layer of moldable material comprising a wax, a gum, a resin, and a flller.

3. A moldable tablet for use in the preparation of electrotype, comprising a sheet of aluminum of predetermined stifiness, la layer of moldable material secured to the sheet, and a 'parting layer in`the exposed surface of the moldable material. w

4. A moldable tablet for use in the preparation of. electrotype, comprising a sheet of aluminum of predetermined stiifness, a layer of moldable material secured to the sheetwhereby the tablet may be molde'dl throughout its entire thickness, including lthe aluminum sheet, to the general contour of a master pattern while receiving the 'speciflc configuration of the pattern in the exposed surface of the moldable material..

5. A moldable tablet for use in the preparation of electrotype, comprising a sheet of aluminum of predetermined stiifness, a layer of moldable material secured to the sheet whereby thetablet may be molded throughout its entire thickness, including the aluminum sheet, to the general contour of a master pattern while receiving the specific configuration of the pattem in the exposed surfaceof the moldable material; and a parting material at the surface of said moldable layer 'to facilitate release of the master pattern transformedafter molding.

6. A moldable tablet for use in the preparation of electrotype, comprising a sheet of aluminum 'accidental defiection in use, the material of said sheet also being sufflciently malleable to 'permit the tablet to be molded throughout its entire thickness, including the aluminum sheet, to the general contour of a master pattern, without rebound. in the sheet, while receiving the specific configuration of the pattern in the exposed surface of the moldable layer.

' 7. A moldable tablet for use in the preparation of electrotype, comprising a relatively thin metallic sheet and a layer of moldable material adhered on the sheet, the material of said sheet being annealed to produce a predetermined ratio between resilience and malleability such that the sheet will normally support the moldable layer substantially resiliently against permanent distortion, the material of said sheet however being substantially malleable to permit the tablet to be molded throughout its entire thickness, including the metallic sheet to the general contour of a master pattern, without rebound, while receiving the specific configuration of the pattern in the exposed surface of. the moldable layer.

8. A moldable tablet as set forth in claim 7, wherein the layer of moldable material comprises a wax, a gum, aresin, and a flller material.

9. A moldable tablet as set forth in claim 7, wherein the material of the moldable layer comprises balata gum and a wax.

10. A moldable tablet as set forth in claim 7, wherein the material of the moldable layer comprises rubber and a wax.

11; A moldable tablet as set forth in claim "l, wherein the material of the moldable layer comprises a resilient gum and a wax.

12. A moldable tablet as set forth inf claim '1, wherein the material of themoldable layer comprlses a Wax ingredient approximately 22% by weight; a resilient gum approximately 22% by surface comprising an intimate 'mixture of wax' and rubber, said ingredients beingproportioned to provide a requisite degree of toughness 'and elasticity to permit accurate, substantially cold molding thereof in contact with a printing form.

14..A moldable tablet foruse in the formation of typographicalv matrices, comprising a sheet tablet having a moldable surface compri'sing an intimate admixture of wax and rubber, less than one-half of the Wax-rubber content comprising rubber, said moldable surface being supported by a relatively rigid backing layer of sheet metal.

15. A moldable tablet for use in the preparation of electrotypes, comprising a malleable, metallic sheet, and a layer of moldable material secured to, the sheet whereby the tablet may be moldedy throughout its thickness to the general contour of a master pattern while receiving the specific configuration of the pattern in the exposed surface of moldable material, said moldable layer comprising an intimate mixture of a wax and rubber, balata or the like.

16. A moldable tablet for use in the Qpreparation of electrotypes, comprising. a malleable metallic sheet, and a layer of moldable .material secured to the sheet whereby the tablet may be molded throughout its thickness to the general contour of a master pattern while receiving the specific configuration of the patterny in the ex-' posed surface of the moldable material; said moldable layer comprising an intimate mixture of a wax and rubber, less than one-half the mixture being rubber.

17. A tablet of the type employed in electrotyping for the production of a matrix by molding in contact with a printing form, said tablet having a supporting layer comprising a sheet of metal and a moldable surface comprising a composition containing wax and rubber intimately mixed.

18. A tablet of the type employed for the production of a matrix by molding in contact with a printing form, said tablet having a supporting layer comprising a sheet of relatively rigid metal the making of typographical matrices by molding in contact with a printing form, comprising a backing layer having sufflcient 'mechanical strength and stiifness to form a support, said backing layer having substantially uniform resistance to deformation in all directions in its plane, and a moldable surface adhering thereto, said surface comprising an intimate mixture of wax and rubber, the rubber being present in a quantity less than that of the wax, said ingredients being proportioned to provide a requisite degree of toughness and elasticity to permit accurate, substantially cold molding thereof in con- -tact with al printing form, said moldable surface layer being formed on the said layer without substantial impregnation thereof.

20. A moldable tablet for use in the formation able surface comprising an intimate admixture' of wax and rubber, less than one-half of the waxrubber content comprising rubber, said moldable surface being supported by a layer of fibrous sheet material, said sheet material having the fibers arranged in random directions and having suflicient mechanical strength to provide a hacking thereforv said moldable surface being formed on the surface of said fibrous layer without substantial impregnation thereof.l j w 21, A moldable tablet for use in the preparation of electrotypes, comprising a continuous supporting sheet formed of a fibrous material in which the fibers are arranged in generally random directions, and a layer' of moldable material supported by the sheet whereby the tablet may he molded throughout its thickness to the general contour of a master pattern while receiving the specific configuration of the pattern in the exposed surface of the moldable material., said moldable layer comprlsing an intimate mixture of a wax and rubber, less than one-half of the mixture being rubber, said moldable layer being formed on the said fibrous layer without substanttal impregnation thereof.

'r LrBBEa'roN. 

